Its your board and up to you what shape size you make it.You will need to follow the manufacturers instruction to get the best result

I would recommend a TT hybrid for your first board you make you can ride both wind directions and will not have to make two boards (port/starboard) I am making a hybrid Shinn pro board which I used from new and was well passed its sell by date Fanatic Kiteboarding DR Gonzo production board So assuming you are making a TT hybrid

The one very important thing you will need a dry warm place to make the board +15c and the board must be dry inside and outI would recommend you get the dispenser pump to get a accurate mixing ratiolist of suppliers for epoxy /fibre glasshttp://www.cfsnet.co.uk/acatalog/CFS_Ca ... TEM_3.html

You may get some of the below on e.bay but you will know what to look for.

These resins are much stronger than polyesters. High performance fabrics such as carbon fibre and kevlar are used to give excellent strength to weight structures. Epoxy resin is much harder,chemical resistant and adheres better than polyester resins. West Multi Purpose Resin is a clear, light-amber, low viscosity epoxy, which, when mixed with the hardener, is formulated to wet out wood, fibreglass and a variety of metals. It can be cured in a wide temperature range to form a high strength solid with excellent moisture resistance. A superb adhesive, 105 Resin will fill gaps and bridge voids when modified with fillers and can be sanded and shaped afterwards. With roller applications, it possesses excellent wet film characteristics by flowing out and self levelling. The epoxy mix cures to a clear finish. Supplied in packs containing the hardener.

West Epoxy Junior Pack 600gm

West Epoxy A Pack 1.2kg Kit Standard hardener can be used in conditions from 5c (Pot life @25c 10-15 mins).Dispenser 301A The calibrated pumps which mount directly onto the resin & hardener containers to ensure accurate dispensing to the correct ratios.301A for A pack. 301B for B pack.301C for C pack.303A pump for special coating hardener.Microfibre Filler 403 150gmA blend of cellulose fibres used as a thickening agent for bonding applications. Epoxy thickened with microfibres provides good wetting out of the substrate and excellent gap filling properties. Add to epoxy mix at 4%-16% by weight. Colour: off white.502 Black Pigment for Epoxy 125gm (optional)

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What a man, excellent information. I'm going to have a good read through all the info before I start with a piece of ply. Hoping to get something made within 4 weeks. Thanks Mike.No laughing here's my work in progress.http://www.flickr.com/photos/gazxtreme/ ... 5/sizes/m/

Last edited by gazxtreme on Tue Nov 17, 2009 10:37 pm, edited 2 times in total.

wood chop board made for Davo yep by me and it worked well PKRA Speed event Port saint Louis France 2007, 5thWest Epoxy A Pack 1.2kg Kit 3 layers of glass on the top and bottomWoven Roving 300gm 100cm wide 3 m only cut it down the middlehttp://www.cfsnet.co.uk/acatalog/CFS_Ca ... c_364.html200gm if you can get it

Last edited by chipmunk on Wed Nov 18, 2009 6:57 pm, edited 1 time in total.

Cut off the excess fibreglass You will need to sand down the uneven surface then fill (do not remove too much fibreglass)U-POL easy 1 is lightweight two component multifunction polyester body filler. Cover with the body filler and sand it down you may have to do this more than once to get a perfect finish

For the professional finish Highly effective polyester spray-filler UPOL 719 Price includes one quart of Reface sprayable polyester primer, great for fibre glass panels and large body filler areas. Includes tube of hardener. Easy to sandThen spray with paint, tins are OK or self mix Never use Polyester products directly on to polystyrene foam this is Why

If you need help PM me and I will send my e-mail /skype

OK that’s it got some more things to do before my Operation hope this was helpfuland has given you the will to make your own Board you can use a lot of this information to repair a damaged board as well good luck and have fun with IT

Hopefully back on the water April /May Davo time to try my new board

Mike P K22

Last edited by chipmunk on Thu Nov 19, 2009 8:12 pm, edited 1 time in total.

Really helpful info, need to get an order of materials together and up-grade my workshop. I live in a town where 1 in 10 people have a boat of some kind and only 1 chandlers that is the equivelent of Halfords, bits of allsorts to do small repairs but nothing to help me build a board.My workshop is open at one end so the temperature has been an issue for the epoxy drying, tonight I've had to pull my chiminea up to the open end and stoke the fire and put a heat lamp in my light fitting Thankfully this is a kind of dry run with an old production board so by the time I've made all my mistakes and got my workshop sealed and heated the real boards can be made properly. Looks like it'stoo windy here on Saturday for teaching so going to try to finish the board tomorrow so it's watertight so I can see if the shape works then spray it up if it's ok.Just one question.... I have an old Mistral Energy on the roof of my school, I was thinking of using the core to make foam blanks for speed boards, would I have to put a ply stringer in like on a surfboard for strenght?Cheers again Mike, great idea for a thread.

Hi Russ no improvement till I get the OP.Trying to do what I can but it takes 3 times as long to do the simple thing

As for a board wood core is the cheapest way to make a dedicated speed board, It will be heavy by modern production board standards

But it will work as Davo proved in France

If I had a vacuum pump I would have made a flex type like Davo has now I would recommend a TT hybrid for your first board but you have to get a board about140 + with straightish sides you can ride both wind directions and will not have to make two boards (port/starboard) You have the foot straps and fins as well

It's finished, well at the stage where it can be used. If it works I will then put a bit finer finish on the board, for know it's the equivelent to the RAT LOOK on a car. It's a bit of an unconventional shape but you never know? possibly should have been painted yellow Pictures of the whole chop and build here http://www.flickr.com/photos/gazxtreme/

Last edited by gazxtreme on Thu Dec 03, 2009 8:12 am, edited 1 time in total.